Warp compensation for additive manufacturing

ABSTRACT

An additive manufacturing method includes receiving a design model indicative of a part that may be fabricated using the additive manufacturing method, and generating expected-warping information based on the design model, the expected-warping information being indicative of an expected change in a shape of the part resulting from the additive manufacturing method. The method also includes modifying the design model based on the expected-warping information and fabricating the part using the modified design model.

TECHNICAL FIELD

Aspects of the present disclosure relate to apparatus and methods forfabricating components. In some instances, aspects of the presentdisclosure relate to apparatus and methods for fabricating components(such as, e.g., automobile parts, medical devices, machine components,consumer products, etc.) via additive manufacturing techniques orprocesses, such as, e.g., 3D printing manufacturing techniques orprocesses.

BACKGROUND

Additive manufacturing techniques and processes generally involve thebuildup of one or more materials to make a net or near net shape (NNS)object, in contrast to subtractive manufacturing methods. Though“additive manufacturing” is an industry standard term (ASTM F2792),additive manufacturing encompasses various manufacturing and prototypingtechniques known under a variety of names, including freeformfabrication, 3D printing, rapid prototyping/tooling, etc. Additivemanufacturing techniques may be used to fabricate simple or complexcomponents from a wide variety of materials. For example, a freestandingobject may be fabricated from a computer-aided design (CAD) model.

A particular type of additive manufacturing is commonly known as 3Dprinting. One such process, which may be referred to as Fused DepositionModeling (FDM) or Fused Layer Modeling (FLM) comprises a process ofmelting a thin layer of thermoplastic material, and applying thismaterial in layers to produce a final part. This is commonlyaccomplished by passing a continuous thin filament of thermoplasticmaterial through a heated nozzle, which melts the material and appliesit to the structure being printed. The heated material is applied to theexisting structure in thin layers, melting and fusing with the existingmaterial to produce a solid finished product.

The filament used in the aforementioned process may be produced by, forexample, using a plastic extruder, which may include steel extruderscrew configured to rotate inside of a heated steel barrel.Thermoplastic material in the form of small pellets may be introducedinto one end of the rotating screw. Friction from the rotating screw,combined with heat from the barrel may soften the plastic, which maythen be forced under pressure through a small round opening in a dieattached to the front of the extruder barrel. This extrudes a string ofmaterial which is cooled and coiled up for use in the 3D printer.

Melting a thin filament of material in order to 3D print an item may bea very slow process, which may be suitable for producing relativelysmall items or a limited number of items. Therefore, the melted filamentapproach to 3D printing may be too slow to manufacture large items.However, the fundamental process of 3D printing using moltenthermoplastic materials may offer advantages for the manufacture oflarger parts or a larger number of items.

In some instances, the process of 3D-printing a part may involve atwo-step process. For example, the process may utilize a large printbead to achieve an accurate final size and shape. This two-step process,commonly referred to as near-net-shape, may begin by printing a part toa size slightly larger than needed, then machining, milling or routingthe part to the final size and shape. The additional time required totrim the part to final size may be compensated for by the fasterprinting process.

Print heads for additive manufacturing machines used to printthermoplastic material in relatively large beads have generally includeda vertically-mounted plastic extruder connected to a print nozzle todeposit the bead of material onto a surface and/or part being printed.The flowable material, such as, e.g., molten thermoplastic material, maybe infused with a reinforcing material (e.g., strands of fiber) toenhance the material's strength. The flowable material, while generallyhot and pliable, may be deposited upon a substrate (e.g., a mold), andthen pressed down or otherwise flattened and/or leveled to a consistentthickness. Traditional print heads may include an oscillating platesurrounding the print nozzle, the plate being configured to oscillatevertically to flatten the bead of material against the surface or parton which bead is deposited, which may include a previously-depositedbead of material. The deposition process may be repeated so that eachsuccessive layer of flowable material may be deposited upon an existinglayer to build up and manufacture a desired structure for a component orpart. In order to achieve proper bonding between printed layers, it maybe necessary to ensure that the temperature of the previously-depositedlayer is within a certain range when a layer is deposited thereon. Forexample, the previously-deposited layer may need to be have cooled to anappropriate degree and thereby have solidified sufficiently to supportthe new layer. However, this previously-deposited layer may need toretrain sufficient heat to soften and fuse with the new layer, thusresulting in a solid part at the conclusion of the manufacturingprocess.

One characteristic of large-scale 3D printed parts, that is notnecessarily characteristic of molding processes, is that each layer maybe applied to an existing layer that is somewhat cooler than thematerial being deposited. This may be mitigated to an extent, as the twomaterials may exchange heat during the print process, as a warmer beadof material may be deposited on a cooler bead of material. However, acertain amount of temperature differential may exist at the junctionbetween each layer. This temperature differential may be sufficientlylarge to cause the part to warp or curl slightly upon cooling to roomtemperature.

The amount of distortion caused by warping may be relatively minimal forsmaller parts (e.g., parts five feet long or less). Since 3D printingmay involve creation of an object that is a near net shape object, thepart may also be designed with additional stock to provide material formachining. For example, the added material may provide sufficientremovable material, or trim stock, on the part such that the subtractivemachining may result in the desired final shape without furtheradjustment. However, at least for some larger parts (e.g., parts tenfeet long or longer), the amount of distortion caused by warping may begreater than the amount of trim stock available, resulting in a part inwhich warping cannot be easily corrected by trimming the part to thedesired size and shape.

One exemplary application for large scale 3D printing is the productionof molds and tooling. These items may be formed with a mold cavity, toolsurface, or other surface which may be provided with a geometry andshape that corresponds to the part the completed mold or tool isintended to process. These molds and tooling may also include additionalmaterial that supports the mold cavity or tool surface. In one aspect,the mold cavity or tool surface may be the most important portion of thefinished part. Thus, it may be beneficial to ensure that the mold cavityor tool surface is formed as accurately as possible. While it may bedesirable to avoid modifying a mold cavity or tool surface, a supportstructure independent of the mold cavity or tool surface may be modifiedwithout affecting the performance of the completed part. It maytherefore be desirable to create a part where, despite the fact that oneor more portions of the part might be warped, such as a supportstructure, the mold cavity or tooling surface is formed in the desiredgeometry and is substantially free of warping.

In an exemplary configuration, X and Y directions may together define aplane parallel to a table top or other print surface, while a Zdirection may define a “stacking” direction of the printed layers. Sincethe part may continuously cool during the print process, warp in the Zdirection may continuously occur on layers which have already beenprinted and are cooling while new layers are printed completely flat andparallel with the print table. As the part grows, the mass of the partmay increase accordingly, and may eventually have sufficient mass toresist warp distortion. Thus, at some point above the table top in the Zdirection, warp distortion within the Z direction may become negligibleor may even be eliminated. Thus, it may be desirable to provide warpcompensation that is applied only to points where warp distortion willoccur. Moreover, warping may also cause distortion to occur in the X andY directions. This warping may be affected by the geometry of the part.For example, on a “C” shaped part, the ends of the “C” may tend to pulltogether when cooling. Thus, it may be desirable to compensate for warpin the X and Y (horizontal) directions, as well as in the Z (vertical)direction.

SUMMARY

Aspects of the present disclosure relate to, among other things, methodsand apparatus for fabricating components via additive manufacturing or3D printing techniques. Each of the aspects disclosed herein may includeone or more of the features described in connection with any of theother disclosed aspects. An object of the warp compensation software isto compensate for the amount the part is expected to warp and create anew program that prints the part so when warping acts to cause the shapeof the part to change to its intended shape. Thus, the final part willhave a shape that corresponds to the shape provided in the originalprogram.

In one aspect, an additive manufacturing method may include receiving adesign model indicative of a part that may be fabricated using theadditive manufacturing method, and generating expected-warpinginformation based on the design model, the expected-warping informationbeing indicative of an expected change in a shape of the part resultingfrom the additive manufacturing method. The method may also includemodifying the design model based on the expected-warping information andfabricating the part using the modified design model.

In another aspect, a method of fabricating a part using an additivemanufacturing apparatus may include receiving a design modelrepresentative of the part and predicting an amount of warping that thepart will experience during cooling. The method may also includemodifying at least a portion of the design model based on the predictedamount of warping and fabricating the part with the additivemanufacturing apparatus based on the modified design model.

In another aspect, an additive manufacturing system may include a memorystoring instructions and at least one processor configured to access thememory and execute the instructions stored in the memory. Theinstructions stored in the memory may include functions for receiving adesign model indicative of a part and generating expected-warpinginformation based on the design model, the expected-warping informationbeing indicative of an expected change in a shape of the part. Theinstructions may also include functions for modifying the design modelbased on the expected-warping information and fabricating the part usingthe modified design model.

Software may be employed to generate predictive data corresponding tothe amount and direction a structure produced by additive manufacturing,such as by 3D printing, will warp upon cooling. This predictive data maybe used to modify information included in the original print program ordesign model to create a warp-offset design model or program which willprint a part that, when the predicted warping occurs, the part may havethe correct size and shape upon cooling.

A first exemplary approach for warp compensation may be employed with awarp-compensating program. In one aspect, the warp-compensating programmay modify the original program or original design model, by warping ordistorting the design model, thereby producing a warp-offset program.For example, the warp-compensating program may warp the original designmodel in a direction that is opposite with respect to a directionpredicted by simulation software configured to predict warping. Suitablewarp-prediction or warp simulation software may be in communicationwith, or provided as a part of, computer aided design (CAD) softwareprogram or CAD system. This warp-prediction software may result in awarp-offset model including bottom layers that are curved rather thanstraight. Since the print program for controlling the additivemanufacturing apparatus may require a flat bottom layer, it maynecessary to add or remove material to the bottom of the model providedto the controller for the additive manufacturing apparatus so that thebottom of the model is flat. This may be performed using suitablefunctions in a CAD program, for example. Appropriate software, such asslicing software, may be employed to add material to the bottom of themodel to provide the flat bottom surface. Depending on the geometry ofthe part and the amount of expected warp, it may also be desirable totrim or add to the top surface of the model so that it is also flat andparallel with the bottom surface. In this adjustment process, it may bebeneficial to ensure that no part of the mold cavity or tool surface isaffected by the addition or subtraction. At this point, the warp-offsetmodel may again be processed through the slicing software to configurethe warp-offset model or program to be processed by a controller for theadditive manufacturing system to manufacture the part.

A second approach to creating a warp-offset program may be performedwithin the control system of the additive manufacturing apparatus orprint machine. For example, the control system of the print machine mayaccept the original program or original design model, and, using datathat predicts point by point how the part will warp when printed andcooled, may modify the original design model to create a second program,or the warp-offset program. This may be performed by creating a secondprint path program using the original print path and predictive data asto how the original printed part will warp.

As each layer of the warp-offset model or program is developed, thesoftware or program that generates the warp-offset model may determinewhere each point of that layer will be located after it warps and usescoordinates of that location from the original design model or partprogram as coordinates for the new point on the warp-offset model orpart program. In that way, when that new point is printed and the partcools and warps, each point of the mold cavity or tool surface will belocated in the desired position.

In this way, the geometry and design of the original unwarped model canbe used to create a print program that will print a part which is atleast partially distorted. When the printed partially-distorted partcools, the mold cavity or tool surface may warp into the desired shape.This approach may ensure that warping distortion of the cooled part islimited to support or trim stock which may be removed by machining,while functional features of the part, such as a mold cavity or toolingsurface, will properly compensate for warping.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings, which are incorporated in and constitute apart of this specification, illustrate exemplary aspects of the presentdisclosure and together with the description, serve to explain theprinciples of the disclosure.

FIG. 1 is a perspective view of an exemplary additive manufacturingapparatus or CNC machine operable pursuant to an additive manufacturingprocess in forming articles, according to an aspect of the presentdisclosure;

FIG. 2 is a perspective view of an exemplary carrier and extruderassembly of the exemplary CNC machine shown in FIG. 1;

FIG. 3 is an enlarged perspective view of an exemplary carrier andapplicator assembly of the exemplary CNC machine shown in FIG. 1;

FIG. 4 is an enlarged cutaway view of an exemplary applicator headassembly shown in FIG. 3;

FIG. 5A is a view of an exemplary CAD image of an original program orCAD model of a printed part with a profile as shown in the slicingsoftware.

FIG. 5B is a view of an exemplary warped model generated bywarp-prediction software based on a profile of an exemplary long part.

FIG. 6A is a view of an exemplary CAD image of a warp compensatedprogram long printed part with a profile.

FIG. 6B is a view of an exemplary long part printed based on the warpcompensated program.

FIG. 7 is an flow chart of an exemplary warp-compensation process thatmay be used with an additive manufacturing apparatus.

DETAILED DESCRIPTION

The present disclosure is drawn to, among other things, methods andapparatus for fabricating one or more components via additivemanufacturing or 3D printing techniques. Specifically, the methods andapparatus described herein may include a warp-compensating programconfigured to compensate for an amount a part may warp. Thewarp-compensating program may be configured to create a new program thatprints the part so the warping acts to the bring the part to a desiredshape. Referring to FIG. 1, additive manufacturing apparatus or CNCmachine 1 may include a bed 20 provided with a pair of transverselyspaced side walls 21 and 22, a printing gantry 23 and trimming gantry 36supported on side walls 21 and 22, a carriage 24 mounted on printinggantry 23, a carrier 25 mounted on carriage 24, and an extruder 61 andan applicator assembly 43 each mounted on carrier 25. A horizontalworktable 27 may be supported on bed 20 between side walls 21 and 22.Horizontal worktable 27 may be provided with a support surface disposedin an x-y plane. Printing gantry 23 and trimming gantry 36 may extendalong a y-axis, supported at the ends thereof on end walls 21 and 22,and may be fixed along an x-axis on a set of guide rails 28 and 29. Asshown in FIG. 1, guide rails 28 and 29 may be provided on the upper endsof side walls 21 and 22. The printing gantry 23 and trimming gantry 36may be displaceable by a set of servomotors respectively mounted on theprinting gantry 23 and trimming gantry 36 and operatively connected totracks provided on the side walls 21 and 22 of the bed 20. Carriage 24may be supported on printing gantry 23 and provided with a supportmember 30 that is displaceably mounted on one or more guide rails 31,32, and 33 on printing gantry 23. Carriage 24 may be displaceable alongthe y-axis and along the one or more guide rails 31, 32 and 33 by aservomotor mounted on the printing gantry 23 and operatively connectedto support member 30. Carrier 25 may be mounted on a set of spaced,vertically-disposed guide rails 34 and 35 supported on the carriage 24for displacing carrier 25 with respect to carriage 24. For example,carrier 25 may be displaceable along the z-axis by a servomotor mountedon the carriage 24 and operatively connected to the carrier 25.

An additive manufacturing system may include CNC machine 1 and acontroller 100. Controller 100 may be configured to output controlsignals to control the various components of CNC machine 1 (e.g.,printing gantry 23, trimming gantry 36, each servomotor of CNC machine1, etc.). Controller 100 may receive feedback from one or morecomponents of CNC machine 1. Moreover, controller 100 may include amemory 102, a display 104, as well as one or more processors that allowcontroller 100 to perform each of the functions described herein. Memory102 may include a suitable non-transitory storage device such as a harddisk drive, solid state drive, USB drive, or any other suitable physicalmedium. Controller 100 may also include a random-access memory and/orread-only memory. Memory 102 may store, for example, a suitablewarp-prediction program, computer-aided design programs, or otherprograms and/or software described herein. Controller 100 may beprovided as a single computing or control device, or may be distributedacross one or more additional devices. Display 104 may be any suitabledisplay, and may be integrated with controller 100 or located at aremote location with respect to controller 100. Display 104 may displayeach of the exemplary CAD models described herein. Display 104 mayinclude a touchscreen or other input device. Controller 100 may alsoinclude any other suitable input device, such as one or more of akeyboard, a touchpad, a mouse, a stylus, etc. Controller 100 may bewirelessly connected to CNC machine 1 or may be connected to machine 1using wires. Electronic signal lines, with the exception of a signalline extending from controller 100 to exemplary printing components ofCNC machine 1, have been omitted for clarity.

As shown in FIG. 2, extruder 61 may be mounted to carrier 25 on a set ofrails 44 and 45 and bearings in a linearly movable manner. Extruder 61may be driven by a servomotor 38, e.g., through a gearbox 39 attached totransition housing 37. Extruder 61 may receive thermoplastic pellets viaa feed housing 40. These pellets may be transferred by an extruder screwthrough barrel 42 where the pellets may melt by heat generated by thefriction of the extruder screw and/or heat generated by heaters 41. Thenextruder 61 may cause molten thermoplastic material provided by themelted pellets to flow to a gear (or melt) pump 62 (FIG. 3).

As shown in FIG. 3, gear pump 62 may be fixedly mounted to the bottom ofcarrier 25. In an exemplary configuration, gear pump 62 may be apositive displacement gear pump, and may be driven by a servomotor 63through a gearbox 64. Gear pump 62 may receive molten plastic fromextruder 61 (FIG. 2), and may meter out precise amounts of thermoplasticmaterial at predetermined flow rates to a nozzle 51 to print the part.The use of both extruder 61 and gear pump 62 rather than an extruderalone may offer the ability to employ extruder screw designs which havedesirable characteristics but which may be unusable in configurationsthat do not include a gear pump, such as extruder screw designs that maytend to cause uneven material flow. The gear pump 62 may provide an evenflow of material regardless of the extruder screw design, therebyproviding a high level of design freedom for the extrusion screw.

A bead shaping roller 59 may be rotationally mounted in carrier bracket47 to provide a means for flattening and leveling an enlarged bead offluid material (e.g., molten thermoplastic) extruded from the nozzle 51.Carrier bracket 47 may be rotationally displaceable by a servomotor 60.In one aspect, servomotor 60 may be operatively connected to carrierbracket 47, through a pulley 56 and belt 65.

With continued reference to FIG. 4, applicator head 43 may include ahousing 46 with rotary union mounted therein. In the exemplaryconfiguration illustrated in FIG. 4, pulley 56 may be machined into theinner hub 76 of the rotary union. Inner hub 76 may include an interioropening large enough in diameter to allow the heated print nozzle 51 topass therein. Inner hub 76 may rotate on a set of bearings 49 providedin the rotary union's outer housing 75. The compression roller assembly(e.g., carrier bracket 47 and compression roller 59) may be attached tothe inner hub 76 of the rotary union so that the compression roller 59rotates about the print nozzle 51. The rotary union may also includebarb fittings 67 and 68 ported into coolant passages 70 that encompassesor surrounds inner hub 76 and the interior of outer housing 75. Thecoolant passages 70 may continue through quick disconnect fittings 72into the axle 73 of the compression roller 59.

As best shown in FIGS. 3 and 4, for example, an oversized molten bead ofa flowable material (e.g., molten thermoplastic) may be provided underpressure from a source disposed on carrier 25 (e.g., gear pump 62) oranother source, to applicator head 43. This material may be provided tonozzle 51 in communication with applicator head 43, which may be fixedlyconnected to carrier 25. In use, the flowable material 53 (e.g.,thermoplastic) may be heated sufficiently to form a large molten bead,which is then extruded through applicator nozzle 51 to formsubstantially uniform, smooth rows of deposited material on a surface ofworktable 27. Such beads of molten material may be flattened, leveled,and/or fused to adjoining layers with substantially no trapped air bybead-shaping compression roller 59 with the layers forming 3D printedproducts.

3D printed products may be manufactured with CNC machine 1 based on oneor more CAD models. In one aspect, a CAD model may be provided on acomputer or control system such as controller 100. CNC machine 1 may beconfigured to produce large parts or products, such as productsextending in a horizontal direction by 10 feet or more. However, CADmodels that correspond to large parts or products (e.g., parts orproducts larger than approximately 10 feet with respect to the x-axisand/or the y-axis) may warp when printed, producing a part that deviatesfrom the CAD model.

FIG. 5A illustrates an exemplary design model or CAD model 86 of arelatively long part, such a tool or a mold having a length or widthgreater than 10 feet. The CAD model 86 of this exemplary part, as shownin FIG. 5A, may correspond to a presentation of 3D CAD model on adisplay, such as display 104 of controller 100. CAD model 86 may be aspresented on display 104 by slicing software. This slicing software maybe a program configured to divide CAD model 86 into a plurality ofslices, or layers, that represent each layer deposited by CNC machine 1to manufacture the part.

With continued reference to FIG. 5A, CAD model 86 may include a portionthat has a substantially C-shaped profile. This C-shape may form a moldor tool cavity 87 of the part. Thus, the resulting part may include amold or tool cavity that corresponds to the cavity 87 in CAD model 86.Trim or support stock portions 88 may be present above and/or below thecavity 87. When manufactured, these portions 88 may form trim stock(e.g., material that may be intended to be trimmed to provide a desiredsurface finish or feature), support stock (e.g., material that isprinted so as to provide support to a portion of the part duringmanufacturing), or both. The trim or support stock portions 88 maycorrespond to portions of the part that are intended to be removed oncethe part has been extruded. Thus, the trim or support stock 88 may beremoved as needed or desired, such as during a finishing or trimmingprocess performed by trimming gantry 36.

Before producing a part corresponding to CAD model 86 with CNC machine1, the CAD model 86 may be loaded (e.g., provided via a removable orpermanent storage medium, transmitted via one or more networks, and/orloaded from memory 102) into a warp-prediction program. Suitablewarp-prediction programs or software may be stored on memory 102 ofcontroller 100, or provided on another suitable device. Thewarp-prediction program may then analyze CAD model 86 and, based on theanalysis, predict the amount of warping, as well as the direction ofwarping, for each location the 3D printed structure of the part that mayexperience warping. This warping may be experienced by the part duringcooling, for example.

FIG. 5B illustrates an example of an expected-warp model 96corresponding to the CAD model 86. Expected-warp model 96 may correspondto predicted-warp information output from the warp-prediction programbased on an analysis of model 86. For example, the warp-predictionprogram may analyze one or more layers of CAD model 86 based onorientation, size (thickness), and the location of adjacent layers orbeads of material. Expected-warp model 96 may represent a simulatedamount of warping that the part, based on CAD model 86, will experienceduring manufacturing and while the part cools. The warp-predicationprogram, after analyzing the CAD model 86, may present expected-warpmodel 96 in an image (e.g., via display 104) that corresponds to thepredicted amount of warping that the part will experience to allow anoperator to observe an amount of predicted warp in each portion of thepart. The expected-warp model 96 may be generated for a portion or anentirety of the model 86 or the part.

When the CAD model 86 is analyzed by the warp prediction-program, theanalysis may determine that, when printed, the ends of the part willwarp or curve upward (away from a surface of worktable 27). Thus,expected-warp model 96 may include ends that are curved upwardly(towards a z-direction and away from a support surface). As can be seenin FIG. 5B, warping may be expected to occur in a lower trim or supportstock portion 98, as well as in mold or tool cavity 97. Depending on theheight of the part, the warp-prediction program may determine that, aparticular height (or particular distance along the z-axis), warping maybe substantially zero. For example, the warp-predication program maydetermine that the upper portion of expected-warp model 96, formed by anupper trim or support stock portion 98, is expected to be substantiallyfree of warping. Depending on the geometry of the part, the heat of themelted thermoplastic material, or other variables, the warp-predictionprogram may instead determine that warping is expected to occur acrossthe entire height of the expected-warp model 96, including an upperportion and/or top surface.

In one aspect, the information provided by the warp-prediction programmay be used to distort or warp the original CAD model 86. For example,CAD model 86 may be modified by using a warp-compensating program orsoftware, such as a CAD program. This program may be the same programused to create CAD model 86, or may be a separate warp-compensatingprogram. Additionally or alternatively, the warp-compensating programmay be provided in the slicing program. The warp compensating-programmay be configured to distort or warp at least a portion of CAD model 86in a direction that is opposite to the predicted warp. This may beperformed via an automated process or a manual process. Thewarp-compensating program may be incorporated within controller 100, ormay be provided in a separate controller or computing device.

FIG. 6A illustrates an example of an intentionally warped or distortedCAD model, such as warp-offset model 106, that may be formed bymodifying CAD model 86 with the warp-compensating program. Warp-offsetmodel 106 may form a modified design model and may include anintentionally distorted or warped portion in at least a portion thereof,such as a lower trim or support stock portion 108. For example, lowerportion 108 may be distorted or warped in a direction opposite to thepredicted warp of expected-warp model 96. In one aspect, an upper or topportion (e.g., an upper trim or support stock portion 108 that may formtrim stock) of the warp-offset model 106 may also be intentionallydistorted or warped in a direction opposite the predicted warp of theupper or top portion of predicted-warp model 96. As these portions 88may correspond to trim or support stock, these portions (the bottomportion, top portion, or both) may be trimmed with trimming gantry 36 ofthe CAD system. Thus, even if trim or support stock of such portions ofthe final part remains warped, warping is limited to portions that areintended for removal or that will not have a deleterious effect on theperformance of the part. Warp-offset model 106 may be processed byslicing software to produce a program configured to operate CNC machine1 to produce a part based on warp-offset model 106.

As mold or tool cavity 107 may be intentionally warped by thewarp-compensating program in a direction opposite to the expectedwarping, the resulting portion in the manufactured part, such as part116 described below, may be formed with a final shape that closelymatches original CAD model 86. For example, a side surface of mold ortool cavity 107 may have a modified horizontal location as compared toCAD model 86. For example, as shown in FIG. 6A, the side surfaces of oneor more layers of mold or tool cavity 107 may be curved in a directionopposite to a curvature of the corresponding mold or tool cavity 97 ofexpected-warp model 96. The mold or tool cavity 107 may be expected towarp and shift in a direction toward mold or tool cavity 87 (FIG. 5A).Thus, while it is possible that trim or support stock portions in theproduced part may be distorted or warped as compared to the exemplaryoriginal CAD model 86, the mold or tool cavity may closely match themold or tool cavity 87 of CAD model 86.

FIG. 6B is an exemplary depiction of a part 116 manufactured based on awarp-modified program. Part 116 may be produced by processingwarp-offset model 106 with slicing software and subsequentlymanufacturing a part based on the processed offset-model 106. Part 116may include an exemplary C-shaped mold or tool cavity 117 free orsubstantially free of any warping. Thus, the mold or tool cavity 117 maymatch the corresponding mold or tool cavity 87 of the original CAD model(FIG. 5A). The extra trim or support stock 118 above and below theC-shape mold or tool cavity 87 may be removed after manufacturing, ifnecessary, (e.g., by machining).

It should be noted that FIGS. 5A-6A illustrate 3D models of an objectthat, in some cases, may be fabricated using CNC machine 1. As would berecognized by persons of ordinary skill in the art, a 3D model is amathematical representation of the surface of the object that, in somecases, is produced by software tools. Since methods of producing 3Dmodels are well known in the art, they are not discussed herein.

With reference to FIG. 7, an exemplary manufacturing method may includeperforming a point-by-point analysis to create a warp-offset program ormodel. In one aspect, the exemplary warp-compensation process may beperformed by a control system or control device (e.g., controller 100)of a manufacturing device such as CNC machine 1. For example, a step 80may include receiving an original program 80. Original program 80 maycorrespond to an unwarped CAD model, such as CAD model 86. Originalprogram 80 may be stored in memory 102, or may be loaded into memory 102in any suitable manner. At step 81, point-by-point predictive data,which may correspond to predicted warping information, may be receivedor generated by controller 100. In one example, step 81 may includegenerating point-by-point predictive data with warp-prediction software.This warp-prediction software may be stored in memory 102 of controller100, or provided via another computing system. The point-by-pointpredictive data may calculate how a plurality of points in one or morelayers of the CAD model 86 may warp when a part printed based on CADmodel 86 cools.

A step 82 may include evaluating the original program of step 80 and thepoint-by-point predictive data of step 81 to determine whether anindividual point of the original program should be modified. This may bedetermined by comparing respective points from steps 80 and 81 todetermine if, for a particular point, warping is expected to occur. Ifwarping is expected to occur, or if the expected warping exceeds apredetermined threshold amount, the data point may be modified based onthe amount and direction of expected warping. For example, step 83 mayinclude determining where the point of will be located after the pointwarps (from the point-by-point predictive data) and uses coordinates ofthis location to modify the corresponding point on the original part(e.g., in a direction opposite to the direction of the expectedwarping). The coordinates of this modified point may be incorporated inthe warp-offset program 85.

Returning to step 82, if warping is not expected to occur for aparticular point, or if expected warping does not exceed a predeterminedthreshold amount, step 82 may proceed to step 84. Step 84 may includepassing the data point, without modification, to the offset -compensatedprogram 85. Thus, the warp-offset program generated in step 85 may bebased on each point evaluated in step 82 and may include a plurality ofunmodified points from the original program, and a plurality of pointsthat were modified based on the difference between a point in theoriginal program and a corresponding point in the point-by-pointpredictive data.

Steps 82, 83, and 84 may be repeated for each point included in theoriginal program until the warp-offset model or program corresponding tothe part is completed. These steps may be performed for each layer of apart in a layer-by-manner manner, by evaluating each of the points of aparticular layer (e.g., a layer generated by slicing software), beforeevaluating points of a subsequent layer. Once these steps have beencompleted, the resulting warp-offset program may include one or morepoints that were modified according to step 83, and one or more pointsthat were not modified according to step 84.

The warp-offset program 85 may then be used to print the part. One ormore working portions, such as a part or entirety of mold or tool cavity117, may experience warping that draws this portion into the positiondefined by the intended mold or tool cavity 87, as represented in CADmodel 86. Thus, the working portions of the resulting part may moreclosely resemble the intended shape, providing a more accuratemanufacturing process. Once the additive manufacturing process iscompleted, trim or support stock 118 of the part 116 may be removed asneeded.

From the foregoing detailed description, it will be evident that thereare a number of changes, adaptations and modifications of the presentinvention which come within the province of those persons havingordinary skill in the art to which the aforementioned inventionpertains. However, it is intended that all such variations not departingfrom the spirit of the invention be considered as within the scopethereof as limited by the appended claims.

1-20. (canceled)
 21. An additive manufacturing method, comprising:receiving, by one or more processors, a design model for an additivemanufacturing apparatus, the design model being indicative of a partformed with a plurality of layers stacked on each other in a verticaldirection, the design model having a portion that is shifted away froman expected warping of the portion; and forming the part based on thedesign model, including the shifted portion, by controlling the additivemanufacturing apparatus, with the one or more processors, to: heat amaterial within an extruder; transfer the material to a nozzle; anddeposit the material from the nozzle, the deposited material having ashape that corresponds to the shape of the design model, to form thepart.
 22. The additive manufacturing method of claim 21, furtherincluding controlling a gantry of the additive manufacturing apparatusbased on the shifted portion to deposit the material as a series oflayers stacked on each other in the vertical direction.
 23. The additivemanufacturing method of claim 21, further including generating anexpected-warping model that indicates an expected amount of warping ofthe part.
 24. The additive manufacturing method of claim 21, wherein theplurality of layers includes at least one layer for support or trimmaterial and at least one layer that corresponds to the shifted portionof the design model.
 25. The additive manufacturing method of claim 24,wherein, in the design model, a cavity is positioned above the at leastone layer for support or trim material.
 26. The additive manufacturingmethod of claim 21, wherein the shifted portion of the design model isshifted horizontally away from the expected warping based onexpected-warping information.
 27. The additive manufacturing method ofclaim 26, wherein the expected-warping information includes a pluralityof points that corresponds to a respective plurality of points in thedesign model, at least one point in the design model having beenmodified based on a difference between the at least one point in thedesign model and a corresponding point of the expected-warpinginformation.
 28. The additive manufacturing method of claim 21, furtherincluding generating an expected-warping model and displaying theexpected-warping model on a display device.
 29. The additivemanufacturing method of claim 21, wherein the part extends at least tenfeet after being formed with the additive manufacturing apparatus. 30.The additive manufacturing method of claim 29, wherein the part is amold or a tool.
 31. A method of forming a part with an additivemanufacturing apparatus, comprising: receiving, by one or moreprocessors, a design model representative of the part, wherein thedesign model includes a plurality of layers stacked on each other in avertical direction; generating, by the one or more processors, anexpected-warping model that corresponds to at least a portion of thedesign model that is modified based on a predicted an amount of warpingthat the part will experience during cooling; modifying at least asection of the design model based on the predicted amount of warping,including shifting a portion of the design model in a direction awayfrom an expected warping of the portion and in a horizontal direction;and forming the part with the additive manufacturing apparatus based onthe modified design model by heating material within an extruder anddepositing the heated material with a nozzle downstream of the extruder.32. The method of claim 31, wherein the method further includes movingthe nozzle of the additive manufacturing apparatus along a path based onthe modified portion of the design model.
 33. The method of claim 31,wherein the design model includes a cavity, the portion corresponding tothe cavity.
 34. The method of claim 33, wherein the plurality of layersincludes at least one layer of support material below the cavity. 35.The method of claim 34, wherein the plurality of layers includes atleast one layer of material above the cavity that is determined to befree of warping based on expected-warping information that correspondsto the design model.
 36. The method of claim 34, further includingremoving the at least one layer of support material.
 37. The method ofclaim 36, wherein the at least one layer of support material is removedwith the additive manufacturing apparatus.
 38. The method of claim 31,wherein the portion of the design model corresponds to a cavity of thepart.
 39. The method of claim 31, wherein the predicted amount ofwarping is produced by performing, with the one or more processors, apoint-by-point analysis of the design model to calculate whether aplurality of points of the design model will warp.
 40. The method ofclaim 31, wherein the heated material includes a thermoplastic material.